Midterm Exam Solution

Manufacturing Automation

Problem 1 (2 pts):

An ADC uses a reference voltage of 50 V and has six bit precision. In four successive sampling
periods, each one second long, the binary data contained in the output register were 100011, 011111,
011011, and 011110. Determine the voltage value of four samplings.

Solution:

Determine the voltage values of four samplings:

Binary number Calculation Values
1 2 3 4 5 6
100011 50•(1•0.5 +0•0.5 +0•0.5 +0•0.5 +1•0.5 +1• 0.5 )= 27.34375
1 2 3 4 5 6
011111 50•(0•0.5 +1•0.5 +1•0.5 +1•0.5 +1•0.5 +1• 0.5 )= 24.21875
011011 50•(0•0.51+1•0.52+1•0.53+0•0.54+1•0.55+1• 0.56)= 21.09375
011110 50•(0•0.51+1•0.52+1•0.53+1•0.54+1•0.55+0• 0.56)= 23.4375

Problem 2 (4 pts):

The positioning table for a component insertion machine uses a stepping motor and leadscrew
mechanism. The design specifications require a table speed of 0.3 m/s and an accuracy = 0.016 mm.
The pitch of the leadscrew = 6.0 mm, and the gear ratio = 2:1 (two turns of the motor for each turn of
the leadscrew). The mechanical errors in the motor, gearbox, leadscrew, and table connection are
characterized by a normal distribution with standard deviation  = 0.002 mm. Determine (a) the
minimum number of step angles in the stepping motor and (b) frequency of the pulse train required to
drive the table at the desired maximum speed.

Solution:

The formula of accuracy: Acc =

 The resolution is: CR = 2 (0.016 - 3•0.002) = 0.02 mm

a) The resolution for stepping motor:
Pitch P
CR  
number of step x ratio n x r

The required number of step is:

P 6
n   150 ( steps)
CR x r 0.02 x 2

b) The rotary velocities of the leadscrew:

0.3m / s
RV   50 (rev / sec.)
6mm
 Frequency of pulse train required:
f  RV * n * r  150  50  2  15000Hz  15kHz

Problem 3 (4 pts):

A cylindrical robot has a T-type wrist axis that can be rotated a total of four rotations (each rotation is
a full 3600). The robot's job requires it to position its wrist with a control resolution of 0.50 between
adjacent addressable points. (a) Determine the number of bits required in the binary register for that
axis in the robot's control memory and (b) convert the position of the wrist at 1056.80 to binary
number.
Solution:
Four rotations -> the total angle to rotate: 4*3600 = 14400
a) The resolution:
L L 1440
CR  n  2n  1    2880
2 1 CR 0.5
2n  2881
n  11.49  n  12
The required number of bits in the binary register is 12.
b) Convert the position of wrist at 1056.80
Bit Compared remainder Binary
value number
1 720 1056.8 1
2 360 336.8 0
3 180 336.8 1
4 90 156.8 1
5 45 66.8 1
6 22.5 21.8 0
7 11.25 21.8 1
8 5.625 10.55 1
9 2.8125 4.925 1
10 1.401625 2.1125 1
11 0.703125 0.710875 1
12 0.3515625 0.00775 0

The position at 1056.80 by binary number: 10 11 10 11 11 10